Three-dimensional structure and elements thereof



April 4, 1961 D. WOOD 2,978,077

THREE-DIMENSIONAL STRUCTURE AND ELEMENTS THEREOF v Filed Dec. 9, 1958 INVENTOR DONALD WOOD ATTORNE United States. P tent O ce i THREE-DIMENSIONAL STRUCTURE AND.

ELEMENTS THEREOF Donald Wood, New York, N.Y., assignor to Hill Cross mpany, Inc., New Y rk; N a corporation of NewYork t Filed Dec. 9 1958, Ser. Np, 779,100

17lClaims. (Cl. 189- 44) The present invention relates to three-dimensional 2,978,077 Patented Apr. 4, 196 1 ments formed economically from strip material. When tion will be combinedto form a complete structure comstructures,-and to elements thereof, and is directed more specifically to a novel and improved three-dimensional structural arrangement, incorporating elements formed of 'strip material, which is characterized by lightness in weight in relation to strength andphysical, bulk; V

In accordance with one aspect of the invention,- an improved structuralelement is provided, which is'formed of elongate strip materialshaped'in a'manner' to provide Substantial physical bulk, in relation to the weight of material used,*and to impart substantial strength to the element. Within the purview of the invention, the structural element may take several. forms, one of which is 'a generally elongate form, achievedby providing "a' first series of bends'in the material followed by a second series'of bends ofa similar nature but in theopposite tion, thestrip'materialis bent around to be secured upon one or more structural layers.

direction. The alternate, opposed series of bendsare. re-

three-dimensional structural element or block of gen- I erally rectangular outline.

In accordance with a more specific aspect of the invention, novel and improved structural elements are formed of elongate strip materialby bending the material successively along axes lying at angles (advantageously to the principal axis of'the strip, and in a manner such that successive portions ofthe strip lie in planesdisposed at right angles. Alternate portions of the bent strip are alike, ,in shape and size, and alternate portions of one type lie in spaced parallel planes, while alternate portions of another typelie .at right angles to and extend between the spaced planes. The arrangement of bends imparts'substantial strength to the strip material and also gives the structural element substantial desirable bulk in relationto its weight, as will appear.

In the principal form of the invention, structural elements of elongate form are assembled in pairs to form a structural sub-combination. Alternate elements are arranged in generally opposed relation, so that correspond- I ing portions of adjacent elements are adjacent one an graph, may be fabricated easily, and substantially without dimensional limitations, using standardized structural eleprising two or more levels'of structural sub-combinations. Accordingly, and'as one'of the specific featuresof the invention, the structural elements are provided, in certain of the portions thereof, with offsetting bends, permitting structural sub-combinationsof one level to nest and interlock with structural sub-combinations on anadjacent level.

: In oneof'the' principalvalternate forms of the inven itself and forrna structural element of generally rectangular outline. Complete structures. suitable particularly for supporting compressive loads may be assembled by interconnecting a plurality of the elements to form In such structural assemblies, adjacent elements, are advantageously offset somewhat, one from the other, so that planes of shear between elements are offset in a desired manner.

For a better understanding of the invention, and for a further discussion of the above and other advantageous features thereof, reference should be made to the follow ing detailed description and to the accompanying drawing, in which:

'Figl l is a top plan view of an advantageous form of structural element, made of elongate strip material and incorporating features of the invention;

Fig. 2 is a front elevation of the structural element of Fig.1;

.Fig. 3 is a cross-sectional view taken along line 33 of Fig. 2;

Fig; 4 is a fragmentary perspective view of a structural sub-combination comprising a pair of oppositely disposed, interconnected structural elements of the type illustrated in Figs. 1-3;

' Fig. 5 is a top plan view, partly in section, of a structure comprised of a pair of structural sub-combinations, of the type shown in Fig; 4, disposed at right angles and on different levels;

Fig. 6 is a fragmentary, cross-sectional view taken generally on line 6-6 of Fig. 5;

Fig. 7 is atop plan view of an alternate form of structural element incorporating the invention; I Fig. 8 is an elevational view of the structural element of Fig. 7, viewing the element along the axis of a diagonal, substantially in the direction indicated at 88 in Fig. 7; and p I Fig. 9 is a perspective view of a structure incorporating a plurality of the structural elements of Figs. 7 and 8.

Referring now to the drawing, and initially to Figs. 1-'-3 thereof, the reference numeral-10 designates generally an advantageous form of structural element according to the invention. The element 10 is formed of strip material, such as strip steel, and may be of indeterminate length. The strip, in its initial form, is flat and straight and has a principal axis extending lengthwise thereof. In accordance with the invention, the original strip m a terial is bent at selected points, along axes disposed at angles to the principal axis of the stripadvantageously, at 45 to the principal axis. The various bends in the strip maybe referred to as first, second, third bends,.e ,te,,

ing the invention, it being understood, however, that, in the fabrication of the element, the bends need not be made in the sequence stated or in any special sequence.

In the element shown in Fig. l, the fiat strip material is provided with a first right angular bend 11 made along an axis disposed at 45 to the principal axis of the strip and providing adjacent, connected portions of the strip lying in planes disposed at right angles. One of the adjacent portions thus formed is designated by the numeral 12 and may be referred to herein as a gusset portion, while the other portion formed by the first bend is designated by the numeral 13 and may be referred to as a web portion.

A predetermined distance from the first bend 11, the strip is provided with a second right angular bend 14, disposed at an angle of 45 with respect to the principal axis of the strip, the bend being made opposite to the first bend 11. That is, considering the first bend 11 as being made in a downward direction, the second 14 is made in an upward direction.

As shown best in Fig. 2, the first and second bends 11, 14, which are parallel but spaced apart a predetermined distance, define between them the limits of the web portion 13. The web portion is substantially in the form of a parallelogram and, in the illustration, lies in a vertical plane, while the gusset portion 12 lies in a horizontal plane.

Connected to the web portion 13, on the right hand side of the second bend 14 is a second gusset portion 15, the limits of which are defined by the bend 14 and by a third right angular bend 16. In accordance with the invention, the bend 16 is made along an axis disposed at 45 to the principal axis of the strip but inclined in a direction opposite to that at which the second bend 14 is inclined. Advantageously, the axes of the respective bends 14, 16 intersect substantially at an edge of the strip, as at 17, so that the gusset portion 15 defined thereby is of triangular form, with its base formed by one edge of the strip and its apex lying substantially on the opposite edge of the strip. The third bend 16 is made in the same direction as the second bend 14-.that,is, upward, so that a second web portion 18 lies in a vertical plane and extends upwardly.

A fourth right angular bend 19 is provided in the strip parallel to the third bend 16 but spaced vertically therefrom. The bend 19 lies at a 45 angle to the principal axis of the strip and forms the upper edge of the web portion 18, which is of parallelogram form equal in size and shape to the first web portion 13. The adjacent web portions 13, 18, as best illustrated in Fig. 1, both lie-in vertical planes, but are disposed at right angles to each other.

The bend 19 forms one edge of a gusset portion 12', which is similar in size and shape to the gusset portion 15 and lies in a plane parallel thereto and spaced therefrom, but is oriented in an opposite direction. The second edge of the gusset portion 12' is defined by a bend 11 similar in all respects to the first bend 11 and constituting, for the purpose of this description, the beginning of a further series of bends similar in all respects to those just described.

As will be apparent in Figs. l-3, the respective bends in the strip are made such that alternate gusset portions 12, 15 lie in parallel planes, spaced a predetermined distance apart, while all corresponding gusset portions 12, 12', etc., 15, 15', etc., lie in the same plane. Likewise, all of the web portions 13, 18, etc., are equal in size and shape and lie in vertical planes, with alternate web portions lying in planes disposed at right angles and corresponding web portions 13, 13', etc., lying in spaced parallel planes.

In the form of the invention above described, the structural element has substantial physical bulk, in

a 4 relation to the fiat strip material from which it is formed, and the formed element is generally linear in form, having a principal axis 20. Alternate gusset portions 12, 15 lie on opposite sides of the principal axis 20, connected by the web portions 13, 18, which are inclined and extend back and forth across the axis 20.

A complete structure incorporating the elements of Figs. 1-3 is advantageously made up of structural subcombinations comprising two or more of the elements placed side by side in opposed relation. Thus, in the sub-combination structure of Fig. 4, a pair of elements 10a, 10b are placed side by side, with the apices of the lower gusset portions 15a of one element opposed to the apices of the lower gusset portions 15b of the other element, though slightly offset therefrom. Although not essential, arranging the adjacent elements 10a, 10b in slightly offset relation is advantageous, in that the web portions 18a, 18b of the respective elements may be overlapped slightly and secured together, by welding, soldering or otherwise, in the overlapped area. In the illustrated assembly, which is representative only, the respective web portions are soldered together in the overlapped area, as at 21.

A typical structural sub-assembly may comprise any number of elements 10, placed side by side, it being generally desirable, however, to utilize an even number of elements. Each adjacent pair of elements forms a series of projections of generally rectangular form. Thus, as indicated in Fig.4, for example, the web portions 13a, 13b and 18a, 18b, all disposed in vertical planes, outline a rectangle or a series of rectangles projecting upward from the plane of the lower gusset portions 15a. Likewise, the addition to the sub-combination structure of a third element (not shown) would result in the formation of a series of similar projections of rectangular outline, projecting downward from the plane of the upper gusset portions 12.

In its most advantageous form, the structural assembly of the invention, illustrated in Figs. 5 and 6, includes two or more structural sub-combinations arranged in layers, one above the other, with the elements of one layer disposed at right angles to the elements of the adjacent layer. To this end, the rectangular, projecting portions of one structural sub-combination are arranged for partial reception within similar projecting portions of the adjacent layer. Such partial reception or nesting of the adj acent layers is accommodated by forming offsets in the web portions 13, 18, as indicated at 22, 23. The oflsets are equal in extent to the thickness of the strip material and advantageously are located about halfway between the planes formed by the upper and lower gusset portions. As indicated in Fig. 4, the ofisets 22,23 are such that the internal dimensions of the lower portion of each rectangular projection are equal to the external dimensions of the upper portion of the projection. This permits adjacent layers to benested and provides shoulders, as indicated at 24, 25 in Fig. 6 aifording direct, column support between adjacent layers.

Using sub-combination structures of the type shown in Fig. 4, in which the projections are rectangular, as distinguished from square, the pairs of the structural elements of adjacent layers must be offset in opposite relation to provide for the proper interfitting or nesting of the rectangular projections formed by pairs of elements disposed at right angles. Thus, in Fig. 5, the element 10a is ofiset to the right, with respect to the element 10d of the same layer, while the respective corresponding elements 10e, 10f are offset in a reverse manner, with the element 10] being offset upward with respect to the element 10e. In this respect, it will be understood that, where desirable or expedient, pairs of elements may be connected together without offsetting, in which case the projections are of square outline, so that the angular orientation ofpairs of elements does not effect the proper interfitting of the projections.

In the structu're of Figs'xS and 6, elements of adjacent layers are secured together by securing overlapping portions of the webs, as by welding, soldering, riveting, etc., andsubstantial strength and rigidity is imparted to the structure by reason of the nesting and interlocking of the elements of one layer with the elements of the adjacent layer or layers. In addition, the web portions 13, 18 of the respective elements extenddiagonally with respect to the principal axes of the elements, interconnecting adjacent, elements inna layer and also adjacent layers of elements. The diagonal disposition of the web portions is also of substantial advantage in resisting forces applied to the structure.

In an alternative form of the invention, illustrated in Figs. 7 and 8, strip material is provided with right angular bends, disposed along axes related at 45 to the principal axis of the strip material and forming triangular gusset portions 30-33, disposed in horizontal planes and web portions 34-37, of parallelogram form, disposed in vertical planes. Whereas in the principal form of the invention, two successive bends are made in one direction, followed by two successive bends made in the opposite direction, all of the bends in the strip are made in the same direction to form the element of Figs. 7 and 8. The bends are so spaced that all of the web and gusset portions are substantially equal in size and shape, so that the strip bends back upon itself, with the end of the web portion 37 meeting the end of the web portion 34. And, advantageously, one of the meeting web portions is provided with a tab, as indicated at 34a, which is bent to overlap with the web portion 37 and is secured provide adjacent gusset and web portions on opposite sides of the bending axes lying in planes disposed at A right angles to each other, the axes of said web portions being disposed at acute angles to the planes of'said gusset portions, the length of strip material having at least fi ve successive bends, and at least certainones of said successive bends being disposed on an axis lying at an angle to the adjacent bend on-one side and parallel thereto, as by welding, soldering, etc., to complete the structural element.

In accordance with the invention, alternate portions of the strip,- in the element of Figs. 7 and 8, are of triangular shape and lie in parallel planes and alternate ones of such portions lie in spaced planes. The arrangement is such that each element is box-like in form, advantageously being square in plane and rectangular in elevation.

A structure formed of the elements of Figs. 7 and 8, which is especially suited for withstanding compressive forces, may be formed by arranging the box-like elements edge to edge and securing together overlapped portions,

as by welding, soldering, etc., substantially as shown in Fig. 9. The elements may be arranged in a variety of ways and in multiple layers in accordance with requirements. However, I have found it desirable to offset adjacent elements, one with respect to the other, so that shear planes, along which adjacent elements are joined, do not extend in a straight line throughout the structure. Similar offsetting may be provided between elements on adjacent levels, where desirable or expedient, as will be readily understood.

In any of its various forms, the structure of the invention is characterized by substantial strength and physical bulk in relation to weight. The elements of the structure are formed by simple bending operations, which may be performed on a four-slide machine, for example, so that the elements may be manufactured economically in great quantity. The new structure may advantageously be used as a high strength filler material, similar to structural honeycomb and, to this end, may be extended in any direction to provide the desired physical bulk.

As will be understood, a substantial variety of structures may be fabricated, within the purview of the invention, depending upon the requirements of the end use. Accordingly, the specific forms of the invention herein illustrated should be considered to be representative only, and reference should be made to the following appended claims in determining the full scope of the invention.

I claim:

1. A structural element comprising a length .of reformed fiat strip material bent successively along axes lying at a 45 degree angle to the axis of the strip to to the adjacent bend on the other side.

2. The structural element of claim 1, in which alternate portions of the bentstrip lie in parallel planes and alternate ones of said alternate portions lie in the same plane.

3. The structural element of claim 2, in which said alternate portions are generally triangular in shape, and alternate ones of the triangular portions are oriented in opposite directions.

4. The structural element of claim 2, in which alternate pairs of bends are made in opposite directions, whereby the structural element is of elongate form and has a principal axis.

5. The structural element of claim 2, in which all bends are made in the same direction.

. 6. The structural element of claim 5, in which alternate portions of the bent strip are of generally triangular shape, and corresponding alternate portions of the strip are substantially equal in dimension, forming a structural element of rectangular outline.

7. A structural element comprising a length of reformed fiat strip material bent successively along axes lying at angles to the axis of the strip to provide adjacent gusset and web portions on opposite sides of the bending axes lying in planes disposed at right angles to each other, alternate pairs of the bends being made in opposite directions whereby the structural element is of elongate form and has a principal axis, the axes of said web portions being disposed at acute angles to the planes of said gusset portions, the length of strip material having at least five successive bends, and at least certain ones of said successive bends being disposed on an axis lying at an angle to the adjacent bend on one side and parallel to the adjacent bend on the other side.

8. The structural element of claim 7, in which the axes of the bends of the alternate pairs intersect and make equal angles with the axis of the strip.

9. The structural element of claim 8, in which the axes of the bends of the said alternate pairs intersect adjacent an edge of the strip to form alternate strip set forth in claim 10, disposed in layers, with the elements of adjacent layers oriented at right angles 'with respect to each other.

12. The mu-lti-layer structure of claim 11, in which projections formed by the structure of one layer are partially received in and thereby interlocked with projections formed by the structure of an adjacent layer.

13. The multi-layer structure of claim 12, in which the portions of the structural elements defining projections are provided with offsets substantially equal to the thickness of the strip material, whereby one projection may be received within another of equal shape and size.

14. A structural element comprising alternate gusset sections of generally triangular shape lying in spaced, parallel planes and alternate ones of which lie in the same plane, and web sections interconnecting the edges of successive gusset sections and lying substantially at right angles to the planes of said gusset sections, the axes of said web sections being disposed at acute angles 7 a. to the planes of said gusset sections, the structural element comprising at least three gusset sections and atleast two web sections.

15. The structure of claim 14, in which the web sections are of parallelogram form. 5 16. The structural element of claim 14, in which successive ones of the generally triangular section are disposed generally along a principal axis to provide an element of elongate, generally linear-form.

17. The structural element of claim 14, which is 10 formed of a single length of flat strip'material.

8 References Citedin the file of this patent UNITED. STATES PATENTS FOREIGN PATENTS Finland Apr. 6, 1948 

